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    New Fashioned Billycart

    Uploaded by

    Antônio Castro
    This document provides instructions for building a modern billycart that is guaranteed to provide children with fun like the old-fashioned wooden billycarts. It lists all the materials needed and gives 12 step-by-step instructions for assembling the billycart, which includes welding various steel parts like the chassis, axles, braces, and push bar together and adding wheels, a seat, steering mechanism, and hand brake. The finished billycart is meant to be painted and padded for safety before use down slopes, recreating the thrill and nostalgia of simple wooden billycarts from the past.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    New Fashioned Billycart

    Uploaded by

    Antônio Castro
    73 views2 pages
    This document provides instructions for building a modern billycart that is guaranteed to provide children with fun like the old-fashioned wooden billycarts. It lists all the materials needed and gives 12 step-by-step instructions for assembling the billycart, which includes welding various steel parts like the chassis, axles, braces, and push bar together and adding wheels, a seat, steering mechanism, and hand brake. The finished billycart is meant to be painted and padded for safety before use down slopes, recreating the thrill and nostalgia of simple wooden billycarts from the past.

    Original Description:

    Paper model e Crafts

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    This document provides instructions for building a modern billycart that is guaranteed to provide children with fun like the old-fashioned wooden billycarts. It lists all the materials needed and gives 12 step-by-step instructions for assembling the billycart, which includes welding various steel parts like the chassis, axles, braces, and push bar together and adding wheels, a seat, steering mechanism, and hand brake. The finished billycart is meant to be painted and padded for safety before use down slopes, recreating the thrill and nostalgia of simple wooden billycarts from the past.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    73 views2 pages

    New Fashioned Billycart

    Uploaded by

    Antônio Castro
    This document provides instructions for building a modern billycart that is guaranteed to provide children with fun like the old-fashioned wooden billycarts. It lists all the materials needed and gives 12 step-by-step instructions for assembling the billycart, which includes welding various steel parts like the chassis, axles, braces, and push bar together and adding wheels, a seat, steering mechanism, and hand brake. The finished billycart is meant to be painted and padded for safety before use down slopes, recreating the thrill and nostalgia of simple wooden billycarts from the past.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 2

    New-fashioned billycart

    Your children will love this modern take on the old-fashioned billycart

    emember the fun you had as a child, whacking some wheels on a couple of bits of wood,
    adding an old fruit box, and pointing the contraption down the nearest slope you could

    find? Well heres the billycart of the new millennium and its guaranteed to be just as much fun.

    Heres how
    Step 1 From rear of chassis beam
    (A), measure 200mm along one side.
    Measure seven further intervals of
    50mm. Draw a line down centre of
    this side and mark hole centres with
    a centre punch. Drill 10mm holes
    through both sides of the chassis. On
    top surface, drill
    a 10mm hole through the beam, 17mm
    from the front.
    Step 2 Drill a 10mm hole in the centre
    of the front axle bar (B), midway along
    its length.
    Step 3 Mark the centre of the back
    axle bar (C) and the centre of the
    end of the chassis beam. Align the
    two marks and check the parts are
    square. Tack-weld in place. If the metal
    is galvanised, set up a fan to blow
    fumes away from you and wear a fume
    mask. Check the angle again, then fully
    weld in place. Weld the end caps (D) to
    the open ends of the bars and beam.

    What youll need


    Item
    A
    B
    C
    D
    E
    F
    G
    H
    I
    J
    K
    L
    M
    N
    O
    P
    Q
    R
    S
    T

    Part
    Chassis beam
    Front axle bar
    Back axle bar
    End caps (5)
    Braces (2)
    Stub axles (4)
    Wheels (4)
    Push/roll bar
    Steering arm
    Chair
    Seat carrier (2)
    Seat spacer (3)
    U-bracket (6 makes 2)
    Sleeve (2)
    Brake rod
    Brake pad (2)
    Spring bracket
    Spring lever
    Spring
    Brake handle

    Size
    35 x 35 x 2.5 x 1250mm
    35 x 35 x 2.5 x 600mm
    35 x 35 x 2.5 x 650mm
    35 x 35 x 2mm
    20 x 20 x 2 x 800mm
    19mm dia x 130mm
    10 x 1.75 (250mm dia)
    35 x 35 x 1.5 x 1660mm
    10mm dia x 1900mm
    20 x 20 x 2 x 320mm
    35 x 2 x 240mm
    35 x 2 x 40mm
    12mm id x 100mm
    12mm dia x 720mm
    35 x 2 x 65mm
    20 x 20 x 2 x 50mm
    12mm dia x 100mm
    75mm
    12mm dia x 520mm

    Material
    Steel square section
    Steel square section
    Steel square section
    Steel bar
    Steel square section
    Steel rod
    Solid steel/rubber
    Steel square section
    Steel rod
    Recycled plastic
    Steel angle
    Steel bar
    Steel bar
    Steel tube
    Steel rod
    Steel bar
    Steel square section
    Steel rod
    Steel
    Steel rod

    Note: id = inside diameter, dia = diameter

    Youll also need: eight 19mm washers; four 3 x 50mm split pins; 100mm x 10mm bolt with
    three washers and nylon locknut; plastic seat without legs; two 50mm bolts and nuts; paint

    Step 4 Mark 30mm in from the ends


    of the rear axle bar. Hold a brace
    (E) with its outside edge on the
    mark and so it just crosses the
    chassis beam. Mark
    the angles, cut, then weld between
    bar and beam. Clean up all welds
    using an angle grinder.
    Step 5 On the underside, draw a
    line along the
    centre of the rear and front axle
    beams. Round the ends of the stub
    axles (F) slightly and drill a 3mm
    hole through the axle, 8mm from the
    outer end. Slip through a split pin,
    add a washer, a wheel (G), then
    another washer. Align axle beams
    with the line and tack-weld at end.
    Check alignment of wheels. Tap
    axle with hammer to adjust. Remove
    wheels or cover with several layers
    of aluminium foil or leather to
    protect against welding spatter. Weld
    axles in place.

    http://www.bhg.com.au

    Step 6 Join the front axle beam to the


    chassis with a 10mm bolt. Slip a washer
    under the bolt head, between the bar
    and the beam, and under the nylon
    locknut.
    Step 7 Set a sliding bevel to 50 and
    draw a V 700mm from each end of the
    push-cum-roll bar (H). Cut out the Vs
    with an angle grinder, without cutting
    through the fourth side. Bend the bar
    to two angles of 100 and weld along
    the seams. Trim off bottoms to a 10
    angle. Centre the bar on the back axle
    and weld.
    Step 8 To bend the steering arm
    (I), measure 175mm from the centre
    of the rod and start a 50mm radius
    right-angle bend by wrapping around
    a 100mm pole. Repeat on other side.
    When bent, the two sides should be
    about 450mm apart. From the bends,
    measure down 470mm and bend both
    sides to about 150. Trim off ends to
    about 125mm long. Centre and weld to
    the front axle bar. Lengthen or shorten
    the steering bar as needed. If you
    find the steering bar awkward to use,
    replace with two eye bolts welded to
    the axle bar and use traditional rope to
    steer the cart.
    Step 9 Seat assembly construction
    depends on the chair (J). Cut the two
    seat carriers (K) and drill holes to
    coincide with the screw holes in the
    seat base. Note the distance they are
    to be apart, and weld them to the three
    spacers (L). Drill a 10mm hole, centred
    19mm from the bottom edge on four of
    the pieces that form the sides of the

    U-bracket (M). Weld the sides to the


    base, then weld to the seat assembly,
    spacing the brackets so their holes
    are 200mm apart and so they coincide
    with the holes in the chassis beam.
    The U-bracket gives four positions of
    adjustment on the beam. Secure with
    bolts.
    Step 10 Slide the sleeves (N) onto the
    brake rod (O). Cover the back wheels
    with foil, and place the brake pad
    (P) on the wheel. Weld the sleeves
    to the push bar, allowing about 3mm
    clearance for the brake pad. The left
    sleeve is fixed flush with the inside of
    the push bar, and the right one sits
    20mm inside the push bar. Weld on the
    brake pads.
    Step 11 Weld the spring bracket (Q) to
    the axle bar. Add the spring lever (R)
    to the brake rod, sloping back a little

    to allow for a few millimetres of travel


    before it hits the axle bar. Add two little
    blobs of weld near the bottom of the
    spring lever to contain the spring. Add
    another two blobs of weld to the
    brake bar, just inside the sleeves,
    to stop lateral movement. Add the
    spring (S) by hooking it into
    the opening of the spring bracket and
    between the blobs on the spring lever.
    Let the spring hold the brake pad in the
    off position, and weld the brake handle
    (T) to the brake bar at a comfortable
    height. Check that the brake pad clears
    the wheels by a few millimetres when
    the spring holds the brake off, yet
    is effective when the brake handle is
    pulled upwards.
    Step 12 Remove seat and wheels, then
    paint the frame, either by brush or by
    applying several coats of spray paint.
    Reassemble all of the components,
    bending the ends of split pins so they
    dont fall out. Tape some padding to the
    steering bar, brake handle and push bar
    (pipe lagging is ideal) and youre ready
    to let her rip.

    http://www.bhg.com.au

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